Synthetic acid compositions alternatives to conventional acids in the oil and gas industry

Abstract

A synthetic acid composition for use in oil industry activities is disclosed. The composition in a preferred embodiment comprises urea and hydrogen chloride in a molar ratio of not less than 0.1:1; and a metal iodide or iodate. Optionally, a phosphonic acid derivative may be added to the composition.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a national stage application under 35 U.S.C. 371 and claims the benefit of PCT Application No. PCT / CA2015 / 000509 having an international filing date of 29 Sep. 2015 (29 Sep. 2015), which designated the United States, which PCT application claimed the benefit of Canadian Patent Application No. 2,866,673 filed 2 Oct. 2014, the entirety of each that are incorporated herein by reference.FIELD OF THE INVENTION[0002]This invention relates to compositions for use in performing various applications in the oil & gas industry, more specifically to synthetic acid compositions as alternatives to conventional acids.BACKGROUND OF THE INVENTION[0003]In the oil & gas industry, stimulation with an acid is performed on a well to increase or restore production. In some instances, a well initially exhibits low permeability, and stimulation is employed to commence production from the reservoir. In other instances, stimulation is used to fu...

AI Technical Summary

Benefits of technology

The present invention provides a synthetic acid composition that can be used in the oil and gas industry for various applications. The composition has advantages such as low corrosion rate, non-fuming, non-toxic, and highly controlled manufacturing process. Additionally, the composition exhibits high salinity tolerance which allows it to be transported as a concentrate safely to the treatment area, then blended with high salinity produced water or sea water greatly reducing the logistics requirement typical with conventional acid systems. The controlled reaction rate of the composition also results in less unintended near wellbore erosion and reduced potential for zonal communication during a typical "open hole" mechanical isolation application treatment. Furthermore, the composition provides a controlled and comprehensive reaction throughout a broad range of temperatures.

Problems solved by technology

Some of the major challenges faced in the oil & gas industry from using hydrochloric acid include the following: extremely high levels of corrosion (which is countered by the addition of ‘filming’ type corrosion inhibitors that are typically themselves toxic and harmful to humans, the environment and equipment) reactions between acids and various types of metals can vary greatly but softer metals, such as aluminum and magnesium, are very susceptible to major effects causing immediate damage.

Hydrochloric acid produces hydrogen chloride gas which is toxic (potentially fatal) and corrosive to skin, eyes and metals.

The inherent environmental effects (organic sterility, poisoning of wildlife etc.) of acids in the event of an unintended or accidental release on surface or downhole into water aquifers or other sources of water are devastating which can cause significant pH reduction of such and can substantially increase the toxicity and could potentially cause a mass culling of aquatic species and potential poisoning of humans or livestock and wildlife exposed to / or drinking the water.

An unintended release at surface can also cause a hydrogen chloride gas cloud to be released, potentially endangering human and animal health.

This is a common event at large storage sites when tanks split or leak.

Because of its acidic nature, hydrogen chloride gas is also corrosive, particularly in the presence of moisture.

The inability for acids and blends of such to biodegrade naturally without neutralizing the soil results in expensive cleanup-reclamation costs for the operator should an unintended release occur.

Moreover, the toxic fumes produced by mineral & organic acids are harmful to humans / animals and are highly corrosive and / or potentially explosive.

Transportation and storage requirements for acids are restrictive and taxing in such that you must haul the products in acid approved tankers or intermediate bulk containers (IBC) that are rated to handle such corrosive products.

As well, the dangers surrounding exposure by personnel handling the blending of such corrosive / dangerous products limits their use / implementation.

Another concern is the potential for exposure incidents on locations due to high corrosion levels of acids causing storage container failures and / or deployment equipment failures i.e. coiled tubing or treatment iron failures caused by high corrosion rates (pitting, cracks, pinholes and major failures).

Other concerns include: downhole equipment failures from corrosion causing the operator to have to execute a work-over and replace down hole pumps, tubing, cables, packers etc.

; inconsistent strength or quality level of mineral & organic acids; potential supply issues based on industrial output levels; high levels of corrosion on surface pumping equipment resulting in expensive repair and maintenance levels for operators and service companies; the requirement of specialized equipment that is purpose built to pump acids greatly increasing the capital expenditures of operators and service companies; and the inability to source a finished product locally or very near its end use; transportation and onsite storage difficulties.

Typically, acids are produced in industrial areas of countries located far from oil & gas applications, up to 10 additives can be required to control various aspects of the acids properties adding to complications in the handling and shipping logistics.

Large price fluctuations of conventional mineral and organic acids based on industrial output capacity causes end users the inability to establish long term cost controls of their respective budgets.

When used to treat scaling issues on surface due to water contamination, conventional acids are exposed to human and mechanical devices as well as expensive pumping equipment causing increased risk for the operator and corrosion effects that damage equipment and create hazardous fumes.

When mixed with bases or higher pH fluids, acids will create a large amount of thermal energy (exothermic reaction) causing potential safety concerns and equipment damage, acids typically need to be blended with fresh water (due to their intolerance of highly saline water, causing potential precipitation of minerals) to the desired concentration requiring companies to pre-blend off-site as opposed to blending on-site with field / produced water thereby increasing costs associated with transportation.

Conventional mineral acids used in a pH control situation can cause rapid degradation of certain polymers / additives requiring increased loadings or chemicals to be added to counter these negative effects.

Many offshore areas of operations have very strict regulatory rules regarding the transportation / handling and deployment of acids causing increased liability and costs for the operator.

When using an acid to pickle tubing or pipe, very careful attention must be paid to the process due to high levels of corrosion, as temperatures increase, the typical additives used to control corrosion levels in acid systems begin to degrade very quickly (due to the inhibitors “plating out” on the steel) causing the acids to become very corrosive and resulting in damage to downhole equipment / tubulars.

Conventional acids are also very destructive to most elastomers found in the oil & gas industry such as those found in blow out preventers (BOP's) / downhole tools / packers / submersible pumps / seals etc.

Having to deal with spent acid during the back flush process is also very expensive as these acids typically are still at a low pH and remain toxic.

The associated dangers that come with using acids are expansive and tasking to mitigate through controls whether they are chemically or mechanically engineered.

Eliminating or even simply reducing the negative effects of acids while maintaining their usefulness is a struggle for the industry.

Scale is caused by the presence of calcium carbonate which is poorly soluble in water and tends to accumulate on surfaces and affect equipment exposed to it.

Some of the disadvantages related to the use of prior art compositions include: inability to export spent product to production facilities due to incompatibilities with fluids / equipment etc. the need to flow or pump the product out of the well and dispose of it prior to bringing the well back on-line; increased transportation / logistics / storage requirements / costs; decreased tolerance for high salinity fluids.

This increases the logistics requirements of potentially requiring the use of fresh water and additional chemistry.

However, such compositions require the additional of a number of various chemical compounds which are dangerous in their undiluted states.

While propargyl alcohol has noted utility in the oil and gas industry, exposure to it through various routes such as inhalation, skin absorption, ingestion, skin and / or eye contact may lead to symptoms including skin irritation, mucous membrane; central nervous system depression, liver, and kidney damage.

It is a toxic / flammable chemical to handle as a concentrate, so care must be taken during handling the concentrate.